Offshore horizontal directional drilling installation frame, system, and method

ABSTRACT

An installation frame for a horizontal directional drilling operation can include a pair of front uprights supporting a front crossbar disposed therebetween and selectively vertically movable. An installation frame can include a pair of rear uprights supporting a rear crossbar disposed therebetween and selectively vertically movable, wherein the front crossbar and the rear crossbar are configured to support a casing for a drill at a predetermined drill angle relative to a floor of a body of water.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 63/314,629, filed on Feb. 28, 2022. The entire disclosure of the above application is incorporated herein by reference.

FIELD

The present disclosure relates to offshore and nearshore marine construction and, more specifically, to a system and method to assist with and streamline the installation of offshore horizontal directional drilling installations in the energy, utility, and marine construction industries.

INTRODUCTION

This section provides background information related to the present disclosure which is not necessarily prior art.

Offshore and nearshore marine construction projects that utilize horizontal directional drilling (HDD) typically involve a specialized equipment such as drilling rigs, usually mounted on a floating barge or elevated platform in a marine setting or on land. Marine HDD projects are generally performed in a water-to-water, or a water-to-land scenario, and an HDD rig can be located on one or both sides of the intended bore.

The basic HDD marine operation can include the following example characteristics:

1) The HDD rig entry and exit angles are usually relatively shallow, for example in the 5-15 degree range from the horizontal (although other angles are possible), meaning that from the point where the drilling rig is located above water to the point where the drilling bit enters the ground can often be several hundred feet.

2) The drilling process utilizes a drilling fluid to aid with the removal of cuttings from the drill face as well as to lubricate and aid with the advance of the cutting bit. The drilling fluid also has the added benefit of helping to cool down the cutting tool as it advances through the ground. While this drilling fluid is composed of natural ingredients (bentonite clay for example) and is environmentally friendly, preventing its release from the drill hole is usually a requirement placed on the works by regulators.

Owing to these above reasons, it is necessary to install both a support and containment system for the drill string between where it leaves/arrives to the platform and when it enters/exits the sea bottom or floor. The drill string used for the initial bore, known as the “pilot hole,” typically includes slender rods that need to be supported or cradled at regular intervals while the drill string is not engaged in the ground. The rods are not designed to span large distances in the fashion that is needed for this type of work in a marine environment.

The general purpose of the HDD operation is to install a final pipe/conduit/casing (i.e., the product pipe). This final product pipe that will ultimately be installed in the bore is usually significantly larger than the pilot bit diameter, the hole needs to be progressively reamed out to the target diameter. The additional soil cuttings generated by this reaming process exit the bore on one side; however, inadvertent returns can occur on either side of the works. In the case of inadvertent returns occurring, they need to be contained so as to not escape into the surrounding environment. This is where a casing sleeve comes into play. Should these inadvertent returns occur, they will be contained within the casing sleeve installed between the HDD rig and the exit/entry location. This casing sleeve will be a larger diameter than the final product pipe as the product pipe will need to be installed inside the casing before the casing can be removed.

Certain methods for supporting the casing sleeve include a “goalpost” system. The goalpost system has two large vertical piles with a crossbar at a specific height on which the casing sleeve will be supported. Several of these goalposts are usually needed (with the crossbar height varying along the alignment) between the HDD rig and the entry pit. The traditional method of installing these goalposts is to build them piece-by-piece in the field, one member at a time which involves a lot of hoisting, equipment, and fabrication, often performed in harsh environments. This traditional method is cumbersome, time consuming, and inefficient.

There is a continuing need for systems and methods for installing structures, such as the aforementioned goalposts, which improve worker safety, reduce the amount of work in the field, and which can be reused from project to project.

SUMMARY

In concordance with the instant disclosure, systems and methods for installing the goalposts which improve worker safety, reduce the amount of work in the field, and which can be reused from project to project, have been surprisingly discovered.

In one embodiment, an installation frame for a horizontal directional drilling operation includes a pair of front uprights, a pair of rear uprights, and bracings disposed between and connecting the front uprights and the rear uprights. The front uprights support a front crossbar that is disposed therebetween, and which is selectively vertically movable. The rear uprights support a rear crossbar that is disposed therebetween, and which is selectively vertically movable. The front crossbar and the rear crossbar are together configured to support a casing for a drill at a predetermined drill angle relative to a floor of a body of water, such as a horizontal directional drilling entry or exit pit.

In another embodiment, a system for horizontal directional drilling on a floor of a body of water can include a plurality of the installation frames. The front and rear uprights of each installation frame are configured to adjust a height of each of the front crossbar and the rear crossbar, respectively, with the height of the front crossbar being equal to or less than the height of the rear crossbar. The system is configured to dispose the casing for the drill on the front crossbar and the rear crossbar of each of the installation frames to provide the casing at a predetermined drill angle relative to floor of the body of water.

In a further embodiment, a method for horizontal directional drilling on a floor of a body of water includes a step of providing a plurality of the installation frames. The method can include a step of adjusting a height of each of the front crossbar and the rear crossbar, with the height of the front crossbar being equal to or less than the height of the rear crossbar. The method can include a step of disposing the casing for the drill on the front crossbar and the rear crossbar of each of the installation frames to provide the casing at a predetermined drill angle relative to floor of the body of water.

In an exemplary embodiment, a system includes several prefabricated frames or bays that provide the ability to drop the frames into the drill alignment at specified locations, with the crossbars set to the correct elevation. These frames can be transported to the project location on a barge or supply vessel and lifted into place. Once the frames are placed, piles can be driven into holes left in the frame (e.g., in the legs) in order to secure each of the frames to the seafloor and provide stability against waves and weather. The final locations of the frames can be surveyed to determine if any final adjustments are needed.

An additional benefit of the frame, system, and method of the present disclosure is that the crossbar member can be adjusted prior to and after installation. The ability to move one or more crossbars provides a huge advantage over previous methods.

Once all frames are installed to the correct geometry, the casing pipe can be placed on the crossbars and the otherwise typical HDD operation can commence. The removal of the frame system after product pipe installation simply involves removing the casing pipe, taking out the holding piles, hooking up the frame to a crane, and hoisting each frame out of the water and onto a nearby vessel.

Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.

DRAWINGS

The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.

FIG. 1 is a top perspective view of a plurality of installation frames positioned to facilitate an installation of a casing on an offshore HDD project, according to an embodiment of the present disclosure;

FIG. 2 is a side elevational view of one of the installation frames shown in FIG. 1 , further illustrating holding piles, base plates, adjustable uprights, and an access walkway of the installation frame, according to an embodiment of the present disclosure;

FIG. 3 is front elevational view of one of the installation frames shown in FIG. 1 , and further illustrating holding piles, base plates, adjustable uprights, and an access walkway of the installation frame, according to an embodiment of the present disclosure; and

FIG. 4 is a flow diagram illustrating a method for installing the installation frames shown in FIGS. 1-3 , according to an embodiment of the present disclosure.

DETAILED DESCRIPTION

The following description of technology is merely exemplary in nature of the subject matter, manufacture and use of one or more inventions, and is not intended to limit the scope, application, or uses of any specific invention claimed in this application or in such other applications as can be filed claiming priority to this application, or patents issuing therefrom. Regarding methods disclosed, the order of the steps presented is exemplary in nature, and thus, the order of the steps can be different in various embodiments, including where certain steps can be simultaneously performed, unless expressly stated otherwise. “A” and “an” as used herein indicate “at least one” of the item is present; a plurality of such items can be present, when possible. Except where otherwise expressly indicated, all numerical quantities in this description are to be understood as modified by the word “about” and all geometric and spatial descriptors are to be understood as modified by the word “substantially” in describing the broadest scope of the technology. “About” when applied to numerical values indicates that the calculation or the measurement allows some slight imprecision in the value (with some approach to exactness in the value; approximately or reasonably close to the value; nearly). If, for some reason, the imprecision provided by “about” and/or “substantially” is not otherwise understood in the art with this ordinary meaning, then “about” and/or “substantially” as used herein indicates at least variations that can arise from ordinary methods of measuring or using such parameters.

Although the open-ended term “comprising,” as a synonym of non-restrictive terms such as including, containing, or having, is used herein to describe and claim embodiments of the present technology, embodiments can alternatively be described using more limiting terms such as “consisting of” or “consisting essentially of.” Thus, for any given embodiment reciting materials, components, or process steps, the present technology also specifically includes embodiments consisting of, or consisting essentially of, such materials, components, or process steps excluding additional materials, components or processes (for consisting of) and excluding additional materials, components or processes affecting the significant properties of the embodiment (for consisting essentially of), even though such additional materials, components or processes are not explicitly recited in this application. For example, recitation of a composition or process reciting elements A, B and C specifically envisions embodiments consisting of, and consisting essentially of, A, B and C, excluding an element D that can be recited in the art, even though element D is not explicitly described as being excluded herein.

Disclosures of ranges are, unless specified otherwise, inclusive of endpoints and include all distinct values and further divided ranges within the entire range. Thus, for example, a range of “from A to B” or “from about A to about B” is inclusive of A and of B. Disclosure of values and ranges of values for specific parameters (such as amounts, weight percentages, etc.) are not exclusive of other values and ranges of values useful herein. It is envisioned that two or more specific exemplified values for a given parameter can define endpoints for a range of values that can be claimed for the parameter. For example, if Parameter X is exemplified herein to have value A and also exemplified to have value Z, it is envisioned that Parameter X can have a range of values from about A to about Z. Similarly, it is envisioned that disclosure of two or more ranges of values for a parameter (whether such ranges are nested, overlapping or distinct) subsume all possible combination of ranges for the value that might be claimed using endpoints of the disclosed ranges. For example, if Parameter X is exemplified herein to have values in the range of 1-10, or 2-9, or 3-8, it is also envisioned that Parameter X can have other ranges of values including 1-9, 1-8, 1-3, 1-2, 2-10, 2-8, 2-3, 3-10, 3-9, and so on.

When an element or layer is referred to as being “on,” “engaged to,” “connected to,” or “coupled to” another element or layer, it can be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers can be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to,” “directly connected to” or “directly coupled to” another element or layer, there can be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.

Although the terms first, second, third, etc. can be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms can be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.

Spatially relative terms, such as “inner,” “outer,” “beneath,” “below,” “lower,” “above,” “upper,” and the like, can be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms can be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” can encompass both an orientation of above and below. The device can be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

The present technology improves upon known systems and methods for supporting a casing for a horizontal directional drilling (HDD) project involving a “goalpost” system. The system includes a series of frames, each of which has large vertical piles with a “crossbar” at a selectable height on which a casing for a drill or pilot bit can be supported. Several frames providing a sufficient number of the crossbars or goalposts are typically employed, with the crossbar heights varying along the alignment, between the HDD rig and the entry pit.

As opposed to other methods of installing such goalposts, which is to build them piece-by-piece in the field, one member at a time, the present system allows for a more efficient and safe method for supporting the casing for the HDD project. Additionally, the present disclosure militates against the need for a lot of hoisting, equipment, and fabrication, often performed in harsh environments.

The system and methods of the present disclosure involve modular installation frames that facilitate a rapid installation of casing support on offshore HDD projects. The system can include a multitude of the frames, which have adjustable goalpost or crossbar heights. The frames will be held in location by piles driven through the frame. Once the geometry of the HDD alignment is known, the crossbar height can be set before installing each of the frames to the seafloor.

It should be appreciated that the majority of the frame can be disposed below a waterline, in operation. The crossbars of the modular installation frames can be selectively adjusted in height in order to provide a desired drill angle at the HDD entry/exist pit, as shown. The crossbar height can either be set at a predetermined height prior to the frame installation, or can be adjusted, e.g., by an actuator controlled by an operator above the waterline, e.g., with a controller or computer or handheld device in communication with the actuator so as to minimize diving time during the installation, at any time prior to receiving the HDD casing for the drill.

The frame can have at least two sets of uprights that are spaced apart from one another by horizontal braces. Each set of uprights can have one of the crossbars selectively movable vertically along a length of the set of uprights. The height of the crossbars can be controlled via an actuator in communication with any suitable mechanism for moving the crossbars vertically up or down, such as threaded rods, gears, pulleys, hydraulic cylinders, pneumatic cylinders, electric motors, and the like, as non-limiting examples. One of ordinary skill in the art can select suitable mechanisms for selectively moving the crossbars of the frame vertically along the length of the uprights, as desired.

It should be appreciated that a bottom of each of the uprights can be a base plate configured to assist in supporting the uprights in a substantially upright orientation relative to the seafloor. Each of the uprights can further have a holding pile or stake that can be passed through each upright or the base plate to allow the holding pile to pass through to the seafloor for securing the frame to the seafloor upon installation. The crossbar on a front side of the frame can be adjusted to a height that is less than the crossbar on a rear side of the frame, so as to provide a desired drill angle for a drill to be disposed through a casing supported by the crossbars in operation. For example, the cross bars can be affixed to side members that are slidably connected to the uprights, and movable vertically, for example, by operation of the actuator as described hereinabove.

It should also be appreciated that an access walkway can be disposed adjacent a top of each of the frames, in order to permit an operator to walk along a length of the system when installing the frames for purposes of adjusting the crossbars to the selected heights. At least one of the walkway and the associated uprights can further have lifting points that permit for the movement and placement of the frames onto the seafloor by cranes or other appropriate equipment, within the scope of the present disclosure. Likewise, the lifting points permit for the removal of the frames from the seafloor upon completion of the HDD project.

EXAMPLES

Example embodiments of the present technology are provided with reference to the several figures enclosed herewith.

With reference to FIGS. 1-3 , an embodiment of a modular system 100 for installation of a casing 101 for a horizontal directional drilling operation is shown. The modular system 100 can include multiple installation frames 102. The installation frames 102 are together configured to support the casing 101 for the drill at a predetermined drill angle (θ) relative to the floor of the body of water.

Each one of the installation frames 102 can include a pair of front uprights 104 supporting a front crossbar 106 disposed therebetween and a pair of rear uprights 108 supporting a rear crossbar 110 disposed therebetween. Each of the front crossbar 106 and the rear crossbar 110 is selectively vertically movable along a height of the respective upright 104, 108. A height of each of the front crossbar 106 and rear crossbar 110 is controlled by an actuator 109 in communication with a mechanism for moving the front crossbar 106 and rear crossbar 110 vertically up or down. The crossbars 106, 110 can be supported on the respective uprights 104, 108 by side supports 111. The side supports 111 can be secured to each of the uprights 104, 108 and can be configured to removably receive the crossbars 106, 110. The actuator 109 can be positioned within at least one of the side supports 111.

The installation frame 102 can further include a pair of base plates 112 configured to assist in supporting the installation frame 102 in a substantially upright orientation relative to the seafloor. One of the base plates 112 can extend from one of the front uprights 104 to the other front upright 104. The other base plate 112 can extend from one upright of the pair of rear uprights 108 to the other rear upright 108. The base plates 112 can include openings 114 formed therethrough. The openings 114 can each receive one of uprights 104, 108. The openings 114 of the base plates 112 can be further configured to receive a holding pile 116. In certain embodiments, the uprights 104, 108 can be hollow and can receive the holding pile 116 therein.

The installation frame 102 can further include bracings 118 disposed between and connecting the front uprights 104 and the rear uprights 108. The bracings 118 can be disposed horizontally between one of the front uprights 104 and one of the rear uprights 108. In some embodiments, multiple bracings 118 can be disposed in an X shape between the front uprights 104 and the rear uprights 108. A skilled artisan can arrange the bracings 118 in any suitable arrangement within the scope of the present disclosure.

The bracings 118 can further include bracings 118 disposed between the pair of front uprights 104 and disposed between the pair of rear uprights 108. The bracings 118 can include permanent bracings and can include interim removable bracings as needed. A skilled artisan can implement bracings 118 as needed to properly secure and stabilize the installation frame 102.

The installation frame 102 can include a walkway 120. The walkway 120 can be disposed across a top of the pair of front uprights 104 and a top of the pair of rear uprights 108. In certain embodiments, the walkway can extend across multiple installation frames 102, in operation. At least one of the uprights 104, 108 and the walkway 120 can include a lifting point 122 that permits the movement and placement of the frame onto the seafloor. A skilled artisan can arrange the lifting points in any suitable arrangement within the scope of the present disclosure.

In operation, and as shown in FIG. 1 , multiple installation frames 102 can be arranged in series such that the crossbars 106, 110 are together aligned to support the casing 101 for the drill at the predetermined drill angle (θ) relative to the floor of the body of water. In particular, the crossbars 106, 110 can increase in height as the frames 102 move away from an end of the drill casing 101. For any given installation frame 102, a height (h1) of the front crossbar 106 can be positioned equal to or less than the height (h2) of a rear crossbar 110, where the crossbar 106, 110 heights of a series of installation frames 102 can be set to maintain the predetermined drill angle (θ) for the casing 101 as the casing 101 spans the series of installation frames 102.

As shown in FIG. 4 , the present disclosure contemplates a method 200 for installation of a modular system for installation of a casing for a horizontal directional drilling operation. A step 202 can include providing multiple installation frames 102, as described herein. A step 204 can include determining the predetermined angle (θ) at which to place the drill casing 101. Based on the predetermined angle (θ), a step 206 can include adjusting a height of each of the front crossbars 106 and the rear crossbars 110, with the height of the front crossbar 106 being equal to or less than the height of the rear crossbar 110 for each of the installation frames 102. A step 208 can include placing the installation frames in series on the floor of the body of water. A step 210 can include adjusting each of the front crossbars 106 and the rear crossbars 110, as needed. A step 212 can include disposing the casing 101 for the drill on the front crossbar 106 and the rear crossbar 110 of each of the installation frames 102 to provide the casing at a predetermined drill angle relative to floor of the body of water.

Advantageously, the installation frame, system, and method as described herein also provide for, as non-limiting examples: i) improved worker safety; ii) improved project schedule; iii) reduced project costs; iv) reduced amount of equipment needed on a project; v) a repetitive system; vi) a modular system; and vii) a reduced installation time. Applications of the installation frame, system, and method of the present disclosure include, as non-limiting examples: a) offshore energy industry; b) offshore utility industry; c) marine salvage industry; and d) marine construction industry.

Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments can be embodied in many different forms, and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail. Equivalent changes, modifications and variations of some embodiments, materials, compositions and methods can be made within the scope of the present technology, with substantially similar results. 

What is claimed is:
 1. An installation frame for a horizontal directional drilling operation, comprising: a pair of front uprights supporting a front crossbar disposed therebetween and selectively vertically movable; a pair of rear uprights supporting a rear crossbar disposed therebetween and selectively vertically movable; a bracing disposed between and connecting one of the front uprights and one of the rear uprights; and wherein the front crossbar and the rear crossbar are configured to support a casing for a drill at a predetermined drill angle relative to a floor of a body of water.
 2. The installation frame of claim 1, wherein a walkway is disposed across a top of each of the pair of front uprights and the pair of rear uprights.
 3. The installation frame of claim 1, further comprising a base plate configured to assist in supporting the installation frame in a substantially upright orientation relative to the seafloor.
 4. The installation frame of claim 3, wherein the base plate extends between the pair of front uprights.
 5. The installation frame of claim 4, further comprising another base plate configured to assist in supporting the installation frame in a substantially upright orientation relative to the seafloor.
 6. The installation frame of claim 5, wherein the another base plate extends between the pair of rear uprights.
 7. The installation frame of claim 3, wherein the base plate includes an opening formed therethrough, the opening receiving one of the front uprights or one of the rear uprights.
 8. The installation frame of claim 7, wherein opening is configured to receive a holding pile.
 9. The installation frame of claim 8, wherein the upright received by the opening is hollow and configured to receive the holding pile.
 10. The installation frame of claim 1, wherein the bracing connects a top portion of one of the front uprights to a bottom of one of the rear uprights.
 11. The installation frame of claim 1, wherein at least one of the front uprights and the rear uprights includes a lifting point that permits for the movement and placement of the frame onto the seafloor.
 12. The installation frame of claim 1, wherein a height of each of the front crossbar and rear crossbar is controlled by an actuator in communication with a mechanism for moving the respective crossbar vertically up or down.
 13. The installation frame of claim 12, wherein the mechanism for moving the respective crossbar vertically up or down includes a member selected from a group consisting of a threaded rod, gear, pulley, hydraulic cylinder, pneumatic cylinder, electric motor, and combinations thereof.
 14. A modular system for installation of a casing for a horizontal directional drilling operation, comprising: a plurality of installation frames disposed in series on a floor of a body of water, each of the installation frames having: a pair of front uprights supporting a front crossbar disposed therebetween and selectively vertically movable; and a pair of rear uprights supporting a rear crossbar disposed therebetween and selectively vertically movable, wherein the front crossbar and the rear crossbar are together configured to support a casing for a drill at a predetermined drill angle relative to the floor of the body of water.
 15. The system of claim 14, wherein a height of the front crossbar being equal to or less than a height of a rear crossbar for each of the installation frames of the plurality of installation frames.
 16. The system of claim 14, wherein a height of the front crossbar and a height of the rear crossbar for each of the installation frames are set to maintain a predetermined drill angle (θ) for the casing as the casing spans the installation frames.
 17. The system of claim 16, further comprising the casing disposed across the front crossbar and the rear crossbar for each of the installation frames at the predetermined drill angle (θ) for the casing as the casing spans the installation frames.
 18. A method for installation a modular system for installation of a casing for a horizontal directional drilling operation: providing a plurality of installation frames, each of the installation frames having a pair of front uprights supporting a front crossbar disposed therebetween and selectively vertically movable; a pair of rear uprights supporting a rear crossbar disposed therebetween and selectively vertically movable; wherein the front crossbar and the rear crossbar are configured to support the casing for the drill at a predetermined drill angle relative to a floor of a body of water; adjusting a height of each of the front crossbar and the rear crossbar, with the height of the front crossbar being equal to or less than the height of the rear crossbar; placing the installation frames in series on the floor of the body of water; and disposing the casing for the drill on the front crossbar and the rear crossbar of each of the installation frames to provide the casing at a predetermined drill angle relative to floor of the body of water.
 19. The method of claim 18, wherein a height of the front crossbar and a height of the rear crossbar for each of the installation frames are set to maintain a predetermined drill angle (θ) for the casing as the casing spans the installation frames.
 20. The method of claim 18, further comprising a step of determining the predetermined angle in order to adjust the height of each of the front crossbar and the rear crossbar. 